Ultra Lightweight Reinforcement for Advanced High-Strength Steel Body and Closures

Transcription

1 Ultra Lightweight Reinforcement for Advanced High-Strength Steel Body and Closures Mansour Mirdamadi Deep Wang Dow Automotive Systems

2 Presentation Outline Introduction to BETAMATE TM epoxy Light Weight Reinforcement (LWR) LWR material performance attributes Component testing studies LWR CAE validation studies Case studies Conclusions

3 BETAMATE Light Weight Reinforcement (LWR) Typical body B-Pillar Structural BETAFOAM Structural BETAMATE LWR What is LWR Body shop applied BETAMATE epoxy material Developed based on characteristics of highly toughened epoxy based adhesive Designed to have expansion characteristics of 150% Designed joint BIW substrates having gaps up to 15 mm Highly mass efficient solution Provide crashworthiness and body stiffness improvement Application method Stream Swirl Bead

4 BETAMATE LWR Expansion Sensitivity Substrate: 0.8mm HDG steel, Temperature exposure 170 C Bond thickness 0.25mm

5 BETAMATE LWR Expansion Sensitivity < 0.5mm 1mm 2mm 3mm 7mm

6 BETAMATE LWR Toughness Performance Wedge impact peel performance of 9.0 N/mm Cohesive failure mode Plastic deformation of the substrate demonstrates BETAMATE LWR toughness

7 Class-A Read Through Studies A: Roof panel to roof bow Observed read through B: B-Pillar No visible read through C: C-Pillar No visible read through

8 Prototype Component Tests All layers are 0.8mm mild steel EG surface 0.75 in 2.0 in welds 5mm gap 120mm 38mm

9 High Speed Component Testing 20 MPH 70 lb mass

10 BETAMATE LWR CAE Correlation Component Bending Response Dynamic Bending Quasi-static

11 Vehicle Crashworthiness Fit

12 B-Pillar Side Impact Component Study Beam 3 point bending study B-Pillar inner: DP590 B-Pillar outer/outer reinforcement: DP980 Requirements Peak load of 50 kn Peak bending moment of 10.5 kn.m Assumptions: 1kg of mass savings worth $5 kg

13 B-Pillar Side Impact Component Study Added LWR mass = 197g B-Pillar outer mm Reinforcement 1.6 mm 1.4 mm Sheet metal saving of 1.0 kg Cost increase delta on based on material $2.67

14 BETAMATE LWR Roof Crush Study

15 BETAMATE LWR Location Sensitivity Study 1.16 kg 0.60 kg 0.18 kg 0.20 kg LWR 3 LWR 4 LWR 5 LWR 9 LWR 6 LWR kg 0.47 kg LWR kg LWR kg LWR kg Total LWR Mass: 4.65 kg

16 The critical locations for LWR LWR 8: B-pillar LWR 1: A-pillar middle joint LWR 7: C-pillar upper joint LWR 3: A pillar upper joint - reinforcement (Negative) LWR 6: Roof rail rear gap The critical interaction variables LWR 3 * LWR 4 LWR 2 * LWR 4 (Negative) LWR 3 * LWR 6 (Negative) BETAMATE LWR Location Sensitivity LWR 8 LWR 6 LWR 7 LWR 1 LWR 3

17 The optimum LWR mass is 1.14 kg Peak force is 63.0 kn, increase 21 % BETAMATE LWR Optimum Locations

18 BETAMATE Application to IIHS Narrow Offset Baseline vehicle response BETAMATE toughened epoxy body flange bonding ~ 100 m BETAMATE LWR body cavity treatment ULWR Optimized #2 0.9kg/side

19 BETAMATE Application to IIHS Narrow Offset Baseline BETAMATE CDA Flange Bonding BETAMATE CDA Flange Bonding & LWR BETAMATE LWR body cavity treatment

20 Narrow Offset Intrusion Comparison Intrusion improvement benefits

21 Conclusions LWR will enable OEMs and Tiers to reinforce small body cavities with highest performance and lowest mass by using proven crash durable bonding technology LWR provides opportunity to Outperform conventional expandable adhesive solutions. Less mass is required in achieving same level of performance Enhance energy absorption and load-transfer between body structure components Join sheet metal components where gaps and joining is not suitable for conventional metal joining or conventional adhesive bonding Optimize body components that are not traditionally considered in design process for meeting new safety and stiffness requirements Body shop applied material using the same dispensing equipment used for BETAMATE adhesive bonding Vehicle body strength/crashworthiness applications IIHS side impact Roof crush Frontal moderate, and narrow offset impact

22 North American Light Vehicle Metallic Material Trends PRESENTATIONS WILL BE AVAILABLE MAY 16 Use your web-enabled device to download the presentations from today s event Great Designs in Steel is Sponsored by: